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Liu G, Liu L, Wang X, Yu J, Ding B. A Fiber Sliding-Orientation Based Micromechanics Failure Model for Melt-Blown Nonwovens. LANGMUIR : THE ACS JOURNAL OF SURFACES AND COLLOIDS 2023; 39:14616-14625. [PMID: 37795881 DOI: 10.1021/acs.langmuir.3c01853] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 10/06/2023]
Abstract
The mechanical model of melt-blown nonwovens (MNs) serves as the foundation for performance optimization, which can offer helpful guidance for product material selection, structural design, and cost control. However, it is challenging to describe the micromechanics failure mechanism of MNs using the traditional mechanical model, which aims to match the model curve with the experimental result at the macrolevel. Herein, a micromechanics failure model for MNs based on sliding-orientation competition is developed. Through in situ observations of fiber position changes and the fluctuation of stress-strain curves, fiber sliding and orientation are introduced into the failure process of MNs. Due to fiber bonding and static friction, only orientation happens during the first stage of stretching. In dramatic contrast, the fibers will slide and orient in the second stage of stretching to change their positions in response to the external force. Sliding friction, fiber bonding, and static friction make up the stress of MNs, and the conflict of fiber sliding and orientation causes variations in the stress. The model has been successfully applied to polylactic acid (PLA) MNs, which proves the effectiveness of the model in MNs.
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Affiliation(s)
- Gaohui Liu
- Key Laboratory of Textile Science & Technology, Ministry of Education, College of Textiles, Donghua University, Shanghai 201620, China
| | - Li Liu
- Tianfangbiao Standardization Certification and Testing Co., Ltd., Tianjin 300300, China
| | - Xianfeng Wang
- Key Laboratory of Textile Science & Technology, Ministry of Education, College of Textiles, Donghua University, Shanghai 201620, China
| | - Jianyong Yu
- Key Laboratory of Textile Science & Technology, Ministry of Education, College of Textiles, Donghua University, Shanghai 201620, China
| | - Bin Ding
- Key Laboratory of Textile Science & Technology, Ministry of Education, College of Textiles, Donghua University, Shanghai 201620, China
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Schuchard KG, Pawar A, Anderson B, Pourdeyhimi B, Shirwaiker RA. Multiphase CFD Modeling and Experimental Validation of Polymer and Attenuating Air Jet Interactions in Nonwoven Annular Melt Blowing. Ind Eng Chem Res 2022; 61:13962-13971. [PMID: 37333487 PMCID: PMC10270699 DOI: 10.1021/acs.iecr.2c01710] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Abstract
In annular melt blowing, fiber formation is achieved by accelerating a molten polymer via drag forces imparted by high velocity air that attenuates the polymer jet diameter. The interactions at the polymer-air interface, which govern the motion of the jets and impact the resulting fiber characteristics, are important but not well understood yet. This work details the development and validation of a multiphase computational fluid dynamics (CFD) model to investigate these interactions and the effects of three key melt blowing process parameters (polymer viscosity and throughput, and air velocity) on two critical fiber attributes - whipping instability and fiber diameter. Simulation results highlighted that whipping instability was driven by the polymer-air velocity differential, and the fiber diameter was primarily modulated by polymer throughput and air velocity. The CFD model was validated by modulating the polymer and air throughputs and analyzing the fiber diameter experimentally. Empirical results showed good agreement between fabricated and model-estimated fiber diameters, especially at lower air velocities. An additional CFD simulation performed using a melt blowing nozzle geometry and process parameters described in literature also confirmed good correlation between model estimates and literature empirical data.
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Affiliation(s)
- Karl G. Schuchard
- Edward P. Fitts Department of Industrial & Systems Engineering, North Carolina State University, Raleigh, NC 27695
- Comparative Medicine Institute, North Carolina State University, Raleigh, NC 27607
| | - Advay Pawar
- Edward P. Fitts Department of Industrial & Systems Engineering, North Carolina State University, Raleigh, NC 27695
- Comparative Medicine Institute, North Carolina State University, Raleigh, NC 27607
| | - Bruce Anderson
- The Nonwovens Institute, North Carolina State University, Raleigh, NC 27606
| | - Behnam Pourdeyhimi
- The Nonwovens Institute, North Carolina State University, Raleigh, NC 27606
| | - Rohan A. Shirwaiker
- Edward P. Fitts Department of Industrial & Systems Engineering, North Carolina State University, Raleigh, NC 27695
- Comparative Medicine Institute, North Carolina State University, Raleigh, NC 27607
- Joint Department of Biomedical Engineering, University of North Carolina at Chapel Hill and North Carolina State University, Raleigh, NC 27695
- Department of Mechanical & Aerospace Engineering, North Carolina State University, Raleigh, NC 27695
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Sun G, Han W, Wang Y, Xin S, Yang J, Zou F, Wang X, Xiao C. Overview of the Fiber Dynamics during Melt Blowing. Ind Eng Chem Res 2022. [DOI: 10.1021/acs.iecr.1c03972] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Guangwu Sun
- Fiber Materials Research Center, School of Textiles and Fashion, Shanghai University of Engineering Science, Shanghai, 201620, P. R. China
- Hainan Vocational University of Science and Technology, Haikou, Hainan Province 571126, P. R. China
| | - Wanli Han
- Materials and Textile Engineering College, Jiaxing University, Jiaxing, Zhejiang Province 314001, P. R. China
| | - Yudong Wang
- College of Biological and Chemical Engineering, Guangxi University of Science and Technology, Liuzhou, Guangxi Zhuang Autonomous Region 545006, P. R. China
| | - Sanfa Xin
- Fiber Materials Research Center, School of Textiles and Fashion, Shanghai University of Engineering Science, Shanghai, 201620, P. R. China
| | - Jingru Yang
- College of Textiles, Donghua University, 201620, Shanghai, P. R. China
- College of Textiles, Zhongyuan University of Technology, Zhengzhou, Henan 450007, P. R. China
| | - Fangdong Zou
- College of Textiles, Donghua University, 201620, Shanghai, P. R. China
| | - Xinhou Wang
- College of Textiles, Donghua University, 201620, Shanghai, P. R. China
| | - Changfa Xiao
- Fiber Materials Research Center, School of Textiles and Fashion, Shanghai University of Engineering Science, Shanghai, 201620, P. R. China
- State Key Laboratory of Separation Membranes and Membrane Processes, Tiangong University, Tianjin, 300387, P. R. China
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Jia J, Xie S, Zhang C. Airflow, Fiber Dynamic Whipping, and Final Fiber Diameter in Flush Sharp-Die Melt Blowing with Different Air-Slot Widths. ACS OMEGA 2021; 6:30012-30018. [PMID: 34778672 PMCID: PMC8582056 DOI: 10.1021/acsomega.1c04689] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 08/27/2021] [Accepted: 10/20/2021] [Indexed: 06/13/2023]
Abstract
Melt streams were attenuated into microfibers by high-speed airflow during melt blowing. The present work explored the effect of air-slot width on the fiber diameter and diameter evenness in flush sharp-die melt blowing. The airflow in different die melt blowing was first numerically simulated by the CFD approach. Then, the fiber dynamic whipping was captured by high-speed photography. Finally, a spinning experiment was implemented and the fiber diameters were measured. The result reveals that the sharp die with a larger air-slot width produces fibers with a larger diameter, but the uniformity is obviously better. This study reveals that the air flow, fiber whipping, and final fiber diameter are closely related to each other. The quality control of melt-blown fiber can be carried out by controlling the fiber whipping motion.
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Affiliation(s)
- Jingjing Jia
- School
of Fashion and Design, Jiaxing Nanhu University, Jiaxing 314001, China
| | - Sheng Xie
- Key
Laboratory of Yarn Materials Forming and Composite Processing Technology
of Zhejiang Province, Jiaxing University, Jiaxing 314001, China
| | - Caidan Zhang
- Key
Laboratory of Yarn Materials Forming and Composite Processing Technology
of Zhejiang Province, Jiaxing University, Jiaxing 314001, China
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Particle Image Velocimetry (PIV) Investigation of the Turbulent Airflow in Slot-Die Melt Blowing. Polymers (Basel) 2020; 12:polym12020279. [PMID: 32023960 PMCID: PMC7077474 DOI: 10.3390/polym12020279] [Citation(s) in RCA: 9] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/30/2019] [Revised: 01/13/2020] [Accepted: 01/21/2020] [Indexed: 11/22/2022] Open
Abstract
In order to explore the forming mechanism of the fiber whipping motion in slot-die melt blowing, the turbulent airflow in slot-die melt blowing was measured online with the approach of the Particle Image Velocimetry (PIV) technique. The PIV results visualized the structure of the turbulent airflow and provided the distributions of air velocity components (vx, vy, and vz). Moreover, the PIV results also demonstrated the evolutive process of turbulent airflow at successive time instants. By comparing the characteristics of the turbulent airflow with the fiber whipping path, the PIV results provide a preliminary explanation for the specific fiber whipping motion in slot-die melt blowing.
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Hao X, Zeng Y. A Review on the Studies of Air Flow Field and Fiber Formation Process during Melt Blowing. Ind Eng Chem Res 2019. [DOI: 10.1021/acs.iecr.9b01694] [Citation(s) in RCA: 37] [Impact Index Per Article: 7.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Xibo Hao
- College of Textiles, Donghua University, Shanghai 201620, China
| | - Yongchun Zeng
- College of Textiles, Donghua University, Shanghai 201620, China
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